Cold spray is well-known to be an attractive method for aerospace repair based on its solid-state deposition nature, demonstrating significant benefits compared to its conventional thermal spray counterparts. However, usage of cold spray for repair within an aviation context is currently limited to geometric restoration for minor damage, including nicks, dents, scratches, and minor corrosion, and will remain limited until the durability and damage tolerance of such repairs can be reliably demonstrated.

Current limitations in this regard surround the manufacturing-dependence of the produced depositions combined with lack of process standardization. In service, the quality of thermal spray coatings are typically evaluated using metrics such as adhesion strength, porosity, and hardness, and these parameters are therefore also often suggested for quality assurance of cold spray deposits. However, it is not clear if these metrics are also suitable and sufficient for assuring the quality of structural repairs.

The present work concerns assessment of the quality of cold spray repairs subjected to high cycle fatigue loading. Fatigue test results for Al6061 cold spray blend-out repair coupons on a like substrate manufactured using different process parameters and surface preparation methods are presented, with an emphasis on variability of, and interactions between, damage modes in fatigue. A comparison between quality metrics used for thermal spray coatings and cold spray fatigue performance are presented.

Acknowledgement: The work presented was supported by the Dutch Research Council Open Technology Programme ‘CSAR’ (grant no: 20434).

Where the trunk of a tree splits into co-dominant branches, wood fibres are highly interlocked. Such an arrangement of fibres has been shown to impart superior strength and toughness to this critical junction. Here, wavy patterns are 3D printed with a liquid crystal polymer (LCP) to evaluate the potential of wood-inspired localized adaptations to improve the robustness of junctions between orthotropic struts. The highly anisotropic, fibrillar microstructure of LCPs is harnessed by Fused Filament Fabrication, yielding Young's modulus and tensile strength reaching 30 GPa and 500 MPa respectively. However, unidirectional 3D-prints subjected to normal tensile stresses show weak interfaces, like in wood. To overcome this weakness, sinusoidal, helix and saw-tooth patterns are 3D-printed to create interlocking between layers. A trade-off is established between uniaxial tension and short-beam shear with increasing interlocking angle of the sinusoidal pattern. We find that the work associated with crack propagation in Mode I is increased three-fold compared to a unidirectional pattern, through extrinsic toughening. When applied to a more complex load case in a curved beam in four-point bending, helix-patterning at the junction zone increases the maximum load by 88 %. By locally controlling anisotropy via waviness, this method opens the possibility of improving toughness and transverse properties where the stress state is multi-axial without adding mass in future recyclable structural materials.

Studies have shown that temperature and moisture play a critical role in altering material properties, with both factors contributing to the overall degradation of structural components. This research aims to provide a deeper insight into the complex interplay between environmental factors and fatigue delamination behaviour in composite materials. To this end, the effect of hygrothermal aging and in-service temperature conditions on mode I fatigue delamination was investigated considering the relationship between fracture surface patterns and fatigue propagation behaviour. To investigate the effects of in-service temperature, Mode I delamination tests followed standardised protocols with pristine (unaged) samples tested at -40, 22, and 80ºC. Hygrothermal ageing (HA) was performed in a climatic chamber at 90ºC and 90% relative humidity for 60 days. After reaching an equilibrium moisture content of 1.2%, the samples were tested at in-service temperature levels of -40, 22, and 80ºC. The in-service humidity was set at 50% in all cases to ensure control of the absorbed moisture under the previous HA conditions. The fatigue curves were remarkbly affected by hygrothermal ageing, as a consequence of the change in the material properties. The individual effect of in-service temperature leads to a temperature-dependent variation in the slope of the da/dN versus dU/dN curves. On the other hand, hygrothermal ageing consistently reduced the slope of all curves, compared to pristine samples (Fig. 1a). The results confirm that temperature inversely affects the slope of the fatigue propagation curve, while hygrothermal ageing promotes a tougher fracture behaviour. The fractography investigation reveals that the surface roughness (Fig. 1b) follows the same trend as the dU/dN slope: higher slopes (lower temperature) correspond to less damage (lower tortuosity), while lower slopes (higher temperature) indicate more damage represented by higher surface roughness.

This study presents a numerical analysis framework of multidirectional (MD) composite laminate under mode I fatigue loading, with calibration to account for fiber bridging. Both local and global methods for calculating the energy release rate are compared. Seven unidirectional (UD) and MD layups were tested, revealing differences in fatigue resistance based on fiber orientation and initial delamination length. Fiber bridging, where fibers stretch across separating plies, was found to enhance toughness. The results show that fiber bridging intensity varies with fiber orientation, with minimal stiffening for the 0°//0° interface and significant stiffening for 90°//90°, 0°//45°, and 0°//90° interfaces.

The development of liquid hydrogen storage systems is a key aspect to enable future clean air transportation. However, safety analysis research for such systems is still limited and is hindered by the limited experience with liquid hydrogen storage in aviation. This paper presents the outcomes of a preliminary safety assessment applied to this new type of storage system, accounting for the hazards of hydrogen. The methodology developed is based on hazard identification and frequency evaluation across all system features to identify the most critical safety concerns. Based on the safety assessment, a set of safety recommendations concerning different subsystems of the liquid hydrogen storage system is proposed, identifying hazard scopes and necessary mitigation actions across various system domains. The presented approach has been proven to be suitable for identifying essential liquid hydrogen hazards despite the novelty of the technology and for providing systematic design recommendations at a relatively early design stage.

This study investigates the Mode-I fracture toughness of laminates with varying interface angles. A method for identifying crack tip location using grayscale characteristic parameters in DIC is proposed. The findings demonstrate that both initial and steady-state fracture toughness exhibit a bilinear relationship with interface angle. A cohesive constitutive model incorporating the interface angle was developed and integrated into a double cantilever beam finite element model, predicting delamination propagation behavior that was highly consistent with experimental results. Numerical analysis suggests that zigzag cracks may improve fracture toughness before steady-state toughness is achieved, with peak toughness correlating to the length of the zigzag cracks.

Fibre bridging is an important phenomenon influencing the mode I delamination growth behaviour in composite materials. Accurate modelling of this phenomenon is required in order to be able to account for its effects in damage tolerance evaluation of composite structures. Therefore, this study introduces a novel physical model to isolate and quantify the contribution of fibre bridging to Mode I fatigue delamination. The model distinguishes between monotonic and cyclic components of fibre bridging stress, capturing their individual effects on the strain energy release rate (SERR) in the Paris curve. The monotonic component, based on the Sørensen model, accounts for pre-cracking effects, while the cyclic component is derived by integrating a bridging stress function over the end-opening displacement, with both components modelled by empirical exponential relationships. The model has been validated against established methods such as the Yao model and specific extrapolation techniques, demonstrating improved accuracy in fitting the Paris curve, particularly in accounting for the monotonic influence in the shift of the SERR and the cyclic contribution to the curve slope. Importantly, the model requires only one quasi-static and one fatigue test, reducing the experimental workload. In conclusion, this method provides a more accurate characterisation of fibre bridging effects, making it a robust tool for fatigue delamination analysis.

Characterisation of the effect of lay-up on the delamination growth revealed a complex set of damage characteristics. Tortuous propagation resulted in higher fibre bridge densification in the off-axis laminates, requiring an increased number of experimental tests to validate the characterisation of fibre bridge saturation effects. The main objective of this research is to apply a modified Sørensen model [1] to measure the fibre bridge (FB) stress curve. In addition, the research aims to estimate the full saturation curve. These objectives will contribute to a more efficient and accurate characterisation of fatigue delamination behaviour in composite materials. The procedure was carried out using a model proposed in the literature [2] for unidirectional composites, to estimate positions of the sull-saturated and fibre bridge Paris curves. The proposed model, based on physical considerations of FB stress formation, was applied to a quasi-static curve and a fatigue curve for each lay-up: 0//0, 0//45 and 0//90. Based on the resulting R-curve, the FB stress curve is derived for each case. This approach accurately models the fatigue behaviour and bridging effects in composites by providing the zero bridging curve (Fig. 1). Following a similar procedure, but now adding the full saturation stress integrated along the end opening delamination, provides the additional strain energy in the steady state region (Fig. 1). This approach allows a more efficient and cost-effective characterisation of fatigue delamination behaviour with a reduced number of experiments, and evaluates the feasibility of applying the proposed model to a single quasi-static and fatigue curve. In addition, the proposed method addresses a comprehensive understanding of fatigue behaviour considering the effect of fibre orientation, thereby contributing to a more comprehensive understanding of fatigue behaviour.

Delamination fatigue propagation is known to cause a progressive degradation of stiffness and strength in composite laminates. Since delamination tends to follow a preferential plane, fracture resistance is conveniently analysed in terms of dominant loading modes at the crack tip: mode I (opening) and mode II (shearing). To this end, coupon tests can be performed to determine the growth rates under these particular stress states. Paris parameters from such tests are then often used in numerical implementations adopting mesoscale modelling, like in the case of cohesive element traction-separation laws. The majority of coupon tests available in the literature focus on interfaces where the fibres of the upper and lower plies have the same orientation, typically aligned with the direction of delamination growth. However, most practical applications involve multidirectional laminates, where delamination tends to develop at interfaces where the upper and lower plies have mismatching angles. Studying angled interfaces may lead to different results since some fracture phenomena, like fibre bridging and crack migration, are highly dependent on fibre orientations of plies adjacent to the delaminated interface [1].
The present work experimentally explored the various effects of fibre orientation on fatigue delamination growth in the different fracture modes. IM7/8552 carbon fibre epoxy prepreg (Hexcel), a material system commonly adopted in aerospace field, was tested under mode I Double Cantilever Beam (DCB), mode II End-Loaded Split (ELS), and Mixed-Mode Bending (MMB) tests. For all cases a combination of different interfacial fibre orientations were tested and the crack growth rate curves were compared in relation to the observed fracture behaviour.

Fibre bridging in laminated composites has a significant effect on Mode I delamination behaviour, resulting in improved opening resistance and altered fatigue crack growth rates. This study investigates the sensitivity of a recently developed superposition model to capture monotonic and cyclic bridging contributions to fatigue delamination. Double cantilever beam (DCB) specimens were tested under quasi-static and cyclic loading to derive R-curves and bridging stress profiles. A set of eleven different parameter combinations were used to generate zero-bridging Paris curves, followed by ANOVA based sensitivity analysis. The results show that the fracture toughness parameters G0 (initiation) and Gs (saturation) have the strongest influence on the Paris parameter coefficients, while the maximum end-opening δ* plays a secondary role. Heat map-based analysis shows that larger differences between G0 and Gs lead to stronger bridging effects and more conservative fatigue curves. This framework provides valuable insight into data-driven calibration of bridging models and supports application-specific fatigue design strategies.

Multidirectional (MD) composite laminates are extensively employed in structural applications owing to their superior mechanical characteristics. Nevertheless, the evaluation of the fracture toughness of composite laminates primarily relies on tests using unidirectional (UD) specimens. This study evaluates the reliability of characterizing mode II delamination behaviour in MD laminates by using UD specimens. The quantification of delamination area through Digital Image Correlation (DIC) analysis is integrated with a physical Energy Release Rate (ERR) method to ascertain the fracture resistance, which is compared with the ERR derived via a modified J-integral method and the standardized compliance methods. Fractographic analysis reveals similar fracture mechanisms in specimens with identical interfaces. The physical ERR increases notably due to large-scale fibre bridging induced by fibre nesting at 0^∘//0^∘ interfaces. Conversely, in 0^∘//90^∘ interfaces, large-area matrix cracking enhances the intrinsic fracture resistance, excluding the extrinsic toughening provided by fibre bridging.

Driven by the energy transition and the reduction of carbon emissions, pultruded CFRP plates have emerged as an affordable high performance material for designing wind turbines with larger rotors. To enable the creation of thicker laminates, pre-cured plates are bonded together using an epoxy resin. The present study focuses on characterizing the fracture behaviours of these laminated bonded plates under different modes, and to generate fracture criteria for numerical simulations establishing design allowables and service life. Double cantilever beam tests, end-loaded split tests, and mixed-mode bending tests were conducted under quasi static loading for such plates. Mode I crack propagation showed brittle failure while mode II fracture tests on the other hand, presented a more stable crack growth. Finally, power law and Benzeggagh-Kenane law criteria were established to numerically describe the fracture behaviours. Overall, the results show that the available standards for fracture toughness testing are also suitable for these laminated-pultruded composite plate structures, enabling the material characterization needed for design.

In this study, a novel experimental approach was devised to investigate shear dominant and combined opening-shear planar delamination behaviours in composite laminates subjected to quasi-static out-of-plane loading. The patterns of planar delamination growth were depicted through different inspection techniques, including digital image correlation (DIC), C-scan, and microscopic observation. The artificially embedded delamination propagated in the direction parallel to the fibre orientation of the layer above the mid interface, but migrated to an upper interface in the direction transverse to the directing ply. A continuous stiffening process was recognized with increasing delamination area. Furthermore, a numerical analysis based on virtual crack closure technique (VCCT) indicated that the local mode II was dominant for delamination growth, while the local mode III triggered delamination migration.

3-D braided composites are a promising material for manufacturing tubular structures. However, a thorough understanding of their damage mechanisms under torsion is required to maximize their potential applications. The present work constructed a multiscale equivalent model, integrating mesoscopic and homogeneous structures to reveal torsional behavior of 3-D braided carbon fiber/epoxy resin composite tubes. The cumulative failure process, spatial stress distribution and interface damage were calculated to illustrate stress transfer and damage initiation and propagation. It is found that stress varies on the surface and internally within the representative unit cell (RUC). The yarns experience both axial tension parallel to the direction of torsion and axial compression perpendicular to the direction of torsion. The stress difference between them leads to damage initiation and propagation. Interfacial cracking as main damage mode hinders the stress transfer between resin and fiber bundles. The results show that the braided yarn path, axial stress dispersion in two directions and localization of damage effectively impede the torsional damage propagation.

Continuous monitoring of spray velocity during the cold spray process would be desirable to support quality control, as spray velocity is the key process parameter determining the deposit quality. This study explores the feasibility of utilising Airborne Acoustic Emission (AAE) for real-time monitoring of spray velocity. Six spray tests were conducted, varying pressure and temperature to achieve different velocities. Optical means were used to measure velocity; while, the signal from the AAE was captured during deposition via a microphone. Features demonstrating a strong correlation with velocity were extracted from the acoustic signals. Both rule-based and machine learning models were employed to identify the moments where the nozzle was engaged with the substrate and diagnose the velocity. The results indicate that monitoring the spray velocity of the cold spray process using AAE is feasible.

This paper investigates the fatigue-induced delamination growth in carbon fibre-reinforced polymer (CFRP), considering different fibre orientation combinations. The study explores the application of Artificial Neural Networks (ANN) in the simulation of fatigue delamination behaviour to reduce the number of experimental tests required for fatigue evaluation and eventual certification. The research aims to evaluate the effectiveness of ANN at different stages of data processing, including raw data simulation and final curve estimation. The results show that applying ANN at the raw data stage provides flexibility in modelling, with error < 10%. In addition, when ANN is applied directly to the final Paris curve, it minimises errors and increases reliability, allowing for a more cost-effective fatigue evaluation process. The study highlights the importance of the data processing stages in determining the accuracy of fatigue delamination predictions with AI modelling, thus informing strategies for efficient fatigue evaluation of CFRP components in structural applications. 

For the past few decades, research into fatigue delamination behaviour of Carbon Fibre Reinforced Polymer (CFRP) composites has predominantly relied on standard test methods. These methods typically utilize a uniaxial delamination length to quantify the fatigue delamination process. However, this approach is inadequate to describe the nature of delamination growth in a planar manner. In this work, an experimental study was conducted to gain insights into the planar delamination behaviour of CFRP composites under mode II fatigue loading. Delamination growth of two specimen configurations, each containing an embedded initial defect, was monitored through ultrasound scanning (C-scan). During load-control fatigue testing, the growth rate exhibited an initial rise, followed by a subsequent decrease as loading cycles increased. Despite the development of a larger delamination area under fatigue loading, a consistent overall stiffness was observed. Fractography revealed the presence of various fracture mechanisms ocurring at different locations near the initial delamination front. Micro matrix cracking and fibre-matrix debonding emerged as dominant mechanisms in 2D fatigue delamination growth following the fibre direction. Matrix cracking within the laminate ply occurred at the locations where the growth direction deviated from the fibre direction, consequently triggering delamination migration.

Laminated pultruded composite plates are gaining interest for use in wind turbine blades due to their excellent structural performance with affordable cost. However, there is limited understanding of their fracture properties. The present work explores the interlaminar fracture behaviour of pultruded composite plates, bonded through resin infusion, to form thick CFRP structures. Mode-I, −II, and mixed-mode (I/II) tests were performed to obtain fracture properties at different mixed-mode ratios. Mode I crack propagation exhibits stick–slip behaviour, resulting in brittle failure in a few steps, while mode II provides more stable crack propagation along with cohesive failure. The mixed-mode fracture patterns follow the trend of the mode-mix ratios, in which higher mode-mix ratios (more mode II) induce more stable crack propagation. Benzeggagh-Kenane and power law criteria were compared regarding their prediction of crack initiation toughness given a mode mix ratio, and a linear relation between the mixed mode I/II fracture toughness components could exist at interfaces of laminated pultruded plates. Meanwhile, applicability of testing standards and the effect of manufacturing-induced defects on fracture properties are thoroughly discussed. The results show that existing standards provide sufficient support for characterising fracture properties of bonded pultruded plates; and that manufacturing-induced defects can be detrimental to crack propagation and cause more brittle behaviour in mode I dominant cases, while beneficial effect of defects by toughening the interface was exhibited in mode II dominant cases.

This article presents an overview of methods for analyzing the facture and failure of adhesives. Special attention is given to stress analysis in adhesive bonds, as the difficulty of performing an accurate stress analysis is a major limitation of many failure analysis methods. The article also covers the effect of manufacturing and operational environment, as well as long-term durability issues such as creep and fatigue.

Delamination growth is a key damage mode threatening the structural integrity of fibre reinforced polymer composite structures. To guide design and damage management of composite structures, research efforts have been made to understand delamination behaviours and establish standardized evaluation methods based mainly on one-dimensional delamination tests. However, as most delamination growth in real structures will be planar, the question arises whether these approaches are adequate to evaluate planar delamination behaviour.
In this study, a novel experimental method was developed to investigate the planar delamination behaviour under quasi-static out-of-plane loading. The planar central loaded split (PCLS) specimen was designed to investigate the planar delamination behaviour under mode II loading condition. By analysing digital image correlation (DIC) and C-scan data, the delamination progress was monitored. An acoustic emission (AE) system was used to capture the initiation of damage and to identify different damage types.
The planar delamination growth was found to be dependent on the stacking sequence and interface properties. Additionally, it was found that positioning a rubber mat between the indenter and the specimen prevented the occurrence of delaminations at undesired interfaces. The artificially embedded delamination propagated in the direction to which the fibre orientation of the layer above the crack interface was parallel, but migrated initially to an upper interface at the place where the fibre was perpendicular. A constant increase in the load was observed even though the delamination propagated. The significant drop of loading seen at the end of the test was attributed to the substantial surface cracking.
The research results provide a clearer understanding of the mechanisms of planar delamination under out-of-plane loading. Furthermore, combining with the experimental results, numerical simulation will be conducted to characterize planar delamination behaviour qualitatively and quantitatively, thus to establish a more reliable assessment method for planar delamination growth